Method of manufacturing electronic devices and corresponding electronic device

ABSTRACT

A first electronic component, such as a sensor having opposed first and second surfaces and a first thickness, is arranged on a support member with the second surface facing towards the support member. A second electronic component, such as an integrated circuit mounted on a substrate and having a second thickness less than the first thickness, is arranged on the support member with a substrate surface opposed the second electronic component facing towards the support member. A package molding material is molded onto the support member to encapsulate the second electronic component while leaving exposed the first surface of the first electronic component. The support member is then removed to expose the second surface of the first electronic component and the substrate surface of the substrate.

PRIORITY CLAIM

This application claims the priority benefit of Italian Application for Patent No. 102019000004835, filed on Apr. 1, 2019, the content of which is hereby incorporated by reference in its entirety to the maximum extent allowable by law.

TECHNICAL FIELD

The description relates to electronic devices.

One or more embodiments may be applied to sensors such as those of a Micro Electro-Mechanical Systems (MEMS) type.

BACKGROUND

Electronic devices including a Micro Electro-Mechanical Systems (MEMS) sensor and an associated “companion” chip such as an Application-Specific Integrated Circuit (ASIC) are now common in the art with the MEMS component mounted onto the companion integrated circuit (IC) chip or arranged on a same substrate as the companion IC chip.

Such devices may be packaged in a full-mold package having a thickness defined by the substrate and the mold chase.

Reducing the total device package thickness is a desirable goal which may be pursued by reducing the substrate thickness and/or reducing the chase thickness by improving process tolerances.

Another option in that direction may involve moving to a Chip Scale Package (CSP) process. It is noted that a CSP approach may not be applicable to MEMS and other sensor structures due to specific features of the associated Front End (FE) processes.

Exposing the “top” side of the semiconductor (silicon) substrate has also been proposed, primarily with the purpose of opening sensing ports in pressure sensors or optical devices, for instance. Exposing the “bottom” side of the substrate has also been proposed in order to improve thermal dissipation from the package.

It is noted that a limiting factor of such approaches is related to the use of a substrate, frame and/or mold compound surrounding (embedding, for instance) the device in its entirety.

There is a need in the art to provide a solution which overcomes the disadvantages outlined in the foregoing.

SUMMARY

One or more embodiments involve arranging side-by-side on a support surface (such as a tape, for instance) a sensor component (a MEMS component, for instance) and a companion chip (an ASIC, for instance) mounted on an associated substrate. After providing electric coupling between the sensor component and the companion chip, a packaging compound is overmolded on the assembly. The support tape is removed so that the resulting package exhibits a final thickness essentially corresponding to the (sole) thickness of the sensor component.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments will now be described, by way of example only, with reference to the annexed figures, wherein:

FIGS. 1A to 1E show steps of a method for making an embodiment,

FIGS. 2A to 2E show steps of a method for making an embodiment,

FIGS. 3A and 3B show a possible variant, and

FIGS. 4A and 4B show another possible variant.

DETAILED DESCRIPTION

In the ensuing description, one or more specific details are illustrated, aimed at providing an in-depth understanding of examples of embodiments of this description. The embodiments may be obtained without one or more of the specific details, or with other methods, components, materials, etc. In other cases, known structures, materials, or operations are not illustrated or described in detail so that certain aspects of embodiments will not be obscured.

Reference to “an embodiment” or “one embodiment” in the framework of the present description is intended to indicate that a particular configuration, structure, or characteristic described in relation to the embodiment is comprised in at least one embodiment. Hence, phrases such as “in an embodiment” or “in one embodiment” that may be present in one or more points of the present description do not necessarily refer to one and the same embodiment. Moreover, particular conformations, structures, or characteristics may be combined in any adequate way in one or more embodiments.

The references used herein are provided merely for convenience and hence do not define the extent of protection or the scope of the embodiments.

One or more embodiments as exemplified herein facilitate providing a full-mold package for an electronic device suited to be produced by resorting to standard and generally available technologies while pursuing a reduction of the total thickness of the resulting device.

One or more embodiments may be applied, for instance, to an electronics device 10 comprising:

-   -   at least one first electronic component 12 such as a sensor (a         MEMS sensor being exemplary of such an component), and     -   at least one second electronic component 14 such as associated         “companion” semiconductor integrated circuit chip or die (an         ASIC being exemplary of such a semiconductor IC chip or die)         mounted on a respective substrate 16.

The designation “respective” highlights the fact that, in one or more embodiments as exemplified herein, the substrate 16 (which may be regarded as akin to a printed circuit board or PCB) is configured to support (only) the semiconductor chip 14 and not the sensor component 12, so that the thickness of the substrate 16 does not add to the thickness of the sensor 12.

As exemplified herein, the first component 12 will exhibit a front or “top” surface 12 a and a rear or “bottom” surface 12 b with a thickness of the component 12 identified by the distance between the surfaces 12 a, 12 b.

As discussed previously, there is a need to reduce the total thickness of the device 10 by letting such a thickness be essentially determined by the thickness of the component 12 (a sensor such as a MEMS, for instance), possibly with both surfaces or sides of the component 12 (namely the front surface 12 a and the back surface 12 b) exposed at the package surface.

In one or more embodiments as portrayed in a first exemplary sequence of processing steps in FIGS. 1A to 1E, a (sacrificial) carrier 20 is provided (FIG. 1A) onto which the component 12 (e.g. a sensor) and a companion component 14 (e.g. a semiconductor chip) are arranged side-by-side with the component 14 mounted on the substrate 16. This may be via bumps 18, as conventional in the art.

FIGS. 1B to 1D are exemplary of processing steps in a manufacturing process which can be performed on a plurality of similar structures or assemblies arranged on a tape-like carrier 20, with these structures eventually separated in a “singulation” step as exemplified in FIG. 1D to provide individual devices 10 (FIG. 1E).

In one or more embodiments, the carrier 20 may include a tape (a polycarbonate tape, for instance) as conventional in manufacturing processes of integrated circuits (ICs).

Once the components 12 and 14 (wherein the component 14 is mounted on the substrate 16) are arranged side-by-side on the carrier 20, with electrical coupling 22 provided therebetween as desired (again by conventional solutions, such as wire bonding, for instance) a package molding compound 24 can be molded onto the previously formed assembly as exemplified in FIG. 1C, that is by leaving exposed the “cap”, namely the front surface 12 a of the component 12.

An Epoxy Molding Compound (EMC) may be exemplary of the package molding compound 24.

FIG. 1D is exemplary of a singulation processing step (performed, in conventional manner, via a singulation tool indicated S) followed by removal of the carrier 20 (FIG. 1E) leading to both the front side or surface 12 a and the rear or back side 12 b of the component 12 being exposed at the surface of the molding material 24.

As a result the package thickness of the device 10 is determined by (that is, essentially the same as) the thickness of the component 12 alone (that is the thickness between the surfaces 12 a, 12 b).

Also, while the opposed surfaces 12 a, 12 b of the component 12 are exposed at the package surface, the material of the component 14 (a semiconductor such as silicon, for instance) is embedded and thus “floating” within the package molding compound 24.

Those of skill in the art will easily appreciate that the sequence of processing steps of FIGS. 1A to 1E is merely exemplary and non-mandatory: for instance, singulation, here exemplified before removal of the carrier 20, may take place after or simultaneously with removal of the carrier 20.

In FIGS. 2A to 2E parts, components or processing steps like parts, components or processing steps already discussed in connection with FIGS. 1A to 1E are indicated with like reference symbols. A corresponding detailed description will not be repeated for brevity.

In embodiments as exemplified in FIGS. 2A to 2E electrical coupling of the component (semiconductor chip) 14 to the substrate 16 is achieved via wire-bonding (again indicated 22) in the place of bumps such as bumps 18 in FIGS. 1B to 1E.

Here again, the package thickness of the device 10 is essentially determined by the thickness of the component 12 alone (that is the thickness between the surfaces 12 a, 12 b), with the possible “height” of the wire bond loops 22 having no practical impact on the total thickness of the device 10 even taking into account the thickness of the component 14 and the substrate (which may be reasonably expected to be thinner than the component 12).

Here again, while the opposed surfaces 12 a, 12 b of the component 12 are exposed at the package surface, the material of the component 14 (a semiconductor such as silicon, for instance) is embedded and thus “floating” within the package molding compound 24.

FIGS. 3A and 3B can be regarded as essentially corresponding to FIGS. 1D and 1E with parts, components or processing steps already discussed in connection with FIGS. 1A to 1E indicated with like reference symbols. A corresponding detailed description will not be repeated for brevity.

FIGS. 3A and 3B are exemplary of the possibility (which may apply both to embodiments as exemplified in FIGS. 1A to 1E and to embodiments as exemplified in FIGS. 2A to 2E) of providing electromagnetic shielding material 26 onto the top or front surface of the component 10 (including the front or top surface 12 a of the component 12).

Such an approach may be advantageous in case the component 12 (a sensor component, for instance) is sensitive to electromagnetic signal.

The shielding material 26 may comprise (in a manner known to those of skill in the art) electrically-conductive material such as a metal which can be applied onto the component 10 after device singulation and possible dedicated substrate design.

FIGS. 4A and 4B can be regarded again as essentially corresponding to FIGS. 1D and 1E with parts, components or processing steps already discussed in connection with FIGS. 1A to 1E indicated with like reference symbols. A corresponding detailed description will not be repeated for brevity.

FIGS. 4A and 4B are exemplary of the possibility (which may apply both to embodiments as exemplified in FIGS. 1A to 1E and to embodiments as exemplified in FIGS. 2A to 2E) of providing a (very) thin sensor—a differential pressure sensor, for instance—with pressure ports 120 provided at the exposed surfaces (for instance both the front surface 12 a and the back surface 12 b) of the sensor component 12.

Also those of skill in the art will appreciated that the stepped outline of the sides of the device in FIGS. 4A and 4B is indicative of the possibility, in one or more embodiments, of providing shielding 26 as exemplified in FIGS. 3A and 3B also in arrangements as exemplified in FIGS. 4A and 4B.

One or more embodiments thus make it possible to reduce the thickness of the device 10 by letting it be essentially given by the thickness of the first component 12 (a MEMS, for instance) without any contribution to the device thickness given by the substrate 16 for the companion component 14 and/or by the mold chase thickness.

In one or more embodiments as exemplified herein the (total) thickness of the molded package (see FIGS. 1E, 2E, 3B and 4B, for instance) is determined by the thickness of a single component (here, the component 12) which, contrary to the component 14, has no associated substrate by avoiding a combination with the substrate and/or mold material thickness.

Also, one or more embodiments lend themselves (in the case of a small routing specifications and/or low signal count, for instance) to implementations where the substrate (16 in the figures) is provided via a copper frame.

Also, certain embodiments (this may be the case of non-capped devices) may facilitate using a component 14 provided with a “dummy” die/interposer mounted on top. This may be advantageous in cases where the exposed front and/or back sides of the component may facilitate (via such a dummy die for instance) a thermal dissipation function and/or a thermal sensing function.

In one or more embodiments, electromagnetic interference (EMI) shielding can be enhanced by resorting to a shielding (metalized, for instance) backside and/or to conductive dummy dies at one or both of the opposed surfaces.

A method as exemplified herein may comprise:

-   -   providing a (planar, for instance) support member (for instance,         20),     -   arranging on the support member:     -   a) at least one first electronic component (for instance, 12)         having opposed first (for instance, 12 a) and second (for         instance, 12 b) surfaces, the at least one first electronic         component arranged on the support member with the second surface         towards the support member, wherein the at least one first         electronic component has a thickness between the opposed first         and second surfaces (for instance, between 12 a and 12 b),     -   b) at least one second electronic component (for instance, 14)         mounted on a substrate (for instance, 16), the at least one         second electronic component arranged on the support member with         the substrate having a substrate surface (facing downwards, in         the figures) opposed the at least one second electronic         component and facing towards the support member, wherein the         substrate and the at least one second electronic component         mounted thereon have a joint (that is, cumulative) thickness         which is less than the thickness of the at least one first         electronic component (see, for instance FIGS. 1B thru 1E, FIGS.         2B thru 2E, 3A and 3B, 4A and 4B),     -   molding package molding material (for instance, 24) onto the         support member having arranged thereon the at least one first         electronic component and the at least one second electronic         component mounted on the substrate, wherein the package molding         material encapsulates the at least one second electronic         component leaving exposed (at the surface of the molding         material) the first surface of the at least one first electronic         component (see, for instance, FIGS. 1C, 2C, 3A and 4A), and     -   separating (removing, for instance) the support member to expose         the second surface of the at least one first electronic         component and the substrate surface of the substrate opposed the         at least one second electronic component (see, for instance,         FIGS. 1E, 2E, 3B and 4B).

A method as exemplified herein may comprise:

-   -   a) providing electrically-conductive formations (for instance,         18 or 22) between:     -   the at least one second electronic component and the substrate         (see, for instance, the bumps 18 in FIGS. 1B to 1E or the wires         22 on the right side of the component 14 in FIGS. 2B to 2E),         and/or     -   the at least one first electronic component and the substrate         (see, for instance, the wires 22 on the right side of the         component 12 in FIGS. 1B to 1E and 2B to 2E), and/or     -   the at least one first electronic component and the at least one         second electronic component (see, for instance, the wires 22         between the components 12 and 14 in FIGS. 2B to 2E),     -   b) molding the package molding material onto the support member         having arranged thereon the at least one first electronic         component and the at least one second electronic component         mounted on the substrate, wherein the package molding material         encapsulates said electrically-conductive formations.

A method as exemplified herein may comprise providing electromagnetic shielding material (for instance, 26) over at least one (for instance, 12 a) of the first and second opposed surfaces of the at least one first electronic component. As discussed a “dummy” shield may be provided on either of both of these surfaces.

In a method as exemplified herein the at least one first electronic component may comprise a pressure sensor with at least one of the opposed first and second surfaces provided with pressure ports (for instance, 120).

In a method as exemplified herein, the support member may comprises a tape.

In a method as exemplified herein:

-   -   the at least one first electronic component may comprise a         sensor, optionally a MEMS, and/or     -   the at least one second electronic component may comprise a         semiconductor integrated circuit chip, optionally an ASIC.

A method as exemplified herein may comprise:

-   -   arranging on the support member a sequence of assemblies,         wherein each assembly may comprise:     -   a) at least one first electronic component having opposed first         and second surfaces, the at least one first electronic component         arranged on the support member with the second surface towards         the support member, wherein the at least one first electronic         component has a thickness between the opposed first and second         surfaces,     -   b) at least one second electronic component mounted on a         substrate, the at least one second electronic component arranged         on the support member with the substrate having a substrate         surface opposed the at least one second electronic component and         facing towards the support member, wherein the substrate and the         at least one second electronic component mounted thereon have a         joint thickness with is less than the thickness of the at least         one first electronic component,     -   molding onto the support member having arranged thereon said         sequence of assemblies, package molding material to encapsulate         the at least one second electronic component in the assemblies         in said sequence of assemblies leaving exposed the first surface         of the at least one electronic component in the assemblies in         said sequence of assemblies,     -   separating the support member to expose the second surface of         the at least one first electronic component and the substrate         surface of the substrate opposed the at least one second         electronic component in the assemblies in said sequence of         assemblies, and     -   singulating (for instance, S) said sequence of assemblies into         individual devices including at least one said first electronic         component and least one said second electronic component coupled         therewith.

A device (for instance, 10) as exemplified herein, may comprise:

-   -   at least one first electronic component having opposed first and         second surfaces, the at least one first electronic component         arranged on the support member with the second surface towards         the support member, wherein the at least one first electronic         component has a thickness between the opposed first and second         surfaces,     -   at least one second electronic component mounted on a substrate,         the at least one second electronic component arranged on the         support member with the substrate having a substrate surface         opposed the at least one second electronic component and facing         towards the support member, wherein the substrate and the at         least one second electronic component mounted thereon have a         joint thickness with is less than the thickness of the at least         one first electronic component, and     -   package molding material encapsulating the at least one second         electronic component leaving exposed the opposed first and         second surfaces of the at least one electronic component and the         substrate surface of the substrate opposed the at least one         second electronic component.

A device as exemplified herein may comprise electrically-conductive formations between:

-   -   the at least one second electronic component and the substrate,         and/or     -   the at least one first electronic component and the substrate,         and/or     -   the at least one first electronic component and the at least one         second electronic component,

wherein said package molding material may encapsulate said electrically-conductive formations.

A device as exemplified herein may comprise electromagnetic shielding material over at least one of the first and second opposed surfaces of the at least one first electronic component.

In a device as exemplified herein the at least one first electronic component may comprise a pressure sensor, with at least one of the opposed first and second surfaces provided with pressure ports.

In a device as exemplified herein:

-   -   the at least one first electronic component (12) may comprise a         sensor, optionally a MEMS, and/or     -   the at least one second electronic component (14) may comprise a         semiconductor chip, optionally an ASIC.

Without prejudice to the underlying principles, the details and embodiments may vary, even significantly, with respect to what has been described by way of example only, without departing from the scope of protection.

The claims are an integral part of the technical disclosure of embodiments as provided herein.

The extent of protection is determined by the annexed claims. 

The invention claimed is:
 1. A method, comprising: arranging a first electronic component on a sacrificial support member, wherein the first electronic component has opposed first and second surfaces with the second surface facing towards the sacrificial support member, wherein the first electronic component has a first thickness between the opposed first and second surfaces; arranging a second electronic component that is mounted to a substrate on said sacrificial support member, wherein the substrate has a substrate surface opposed the second electronic component and facing towards the sacrificial support member, wherein the substrate and the second electronic component combined have a second thickness which is less than the first thickness; molding a package molding material onto the sacrificial support member to encapsulate the second electronic component while leaving the first surface of the first electronic component exposed; and completely removing the sacrificial support member to expose the second surface of the first electronic component and the substrate surface of the substrate.
 2. The method of claim 1, further comprising, prior to molding, providing electrically-conductive formations between the second electronic component and the substrate, wherein the package molding material encapsulates said electrically-conductive formations.
 3. The method of claim 1, further comprising, prior to molding, providing electrically-conductive formations between the first electronic component and the substrate, wherein the package molding material encapsulates said electrically-conductive formations.
 4. The method of claim 1, further comprising, prior to molding, providing electrically-conductive formations between the first electronic component and the second electronic component, wherein the package molding material encapsulates said electrically-conductive formations.
 5. The method of claim 1, further comprising, after molding, mounting an electromagnetic shielding material over at least one of the first and second opposed surfaces of the first electronic component.
 6. The method of claim 1, wherein the first electronic component comprises a pressure sensor and wherein the method further comprises providing a pressure port at one or more of the opposed first and second surfaces.
 7. The method of claim 1, wherein the sacrificial support member comprises a tape.
 8. The method of claim 1, wherein the first electronic component comprises a sensor and the second electronic component comprises a semiconductor integrated circuit chip.
 9. The method of claim 8, where the sensor is a Micro Electro-Mechanical Systems (MEMS) type sensor and wherein the semiconductor integrated circuit chip is an Application-Specific Integrated Circuit (ASIC).
 10. A method, comprising: arranging plurality of assemblies on a sacrificial support member, where each assembly comprises: a first electronic component having opposed first and second surfaces with the second surface facing towards the sacrificial support member, wherein the first electronic component has a first thickness between the opposed first and second surfaces; and a second electronic component that is mounted to a substrate, wherein the substrate has a substrate surface opposed the second electronic component and facing towards the sacrificial support member, wherein the substrate and the second electronic component combined have a second thickness which is less than the first thickness; molding a package molding material onto the sacrificial support member to encapsulate the second electronic components of the plurality of assemblies while leaving the first surface of the first electronic components of the plurality of assemblies exposed; completely removing the sacrificial support member to expose the second surface of the first electronic component and the substrate surface of the substrate; and singulating said plurality of assemblies into individual devices, wherein each individual device includes the first electronic component and the second electronic component.
 11. The method of claim 10, further comprising, prior to molding, providing electrically-conductive formations for each assembly between the second electronic component and the substrate, wherein the package molding material encapsulates said electrically-conductive formations.
 12. The method of claim 10, further comprising, prior to molding, providing electrically-conductive formations for each assembly between the first electronic component and the substrate, wherein the package molding material encapsulates said electrically-conductive formations.
 13. The method of claim 10 further comprising, prior to molding, providing electrically-conductive formations for each assembly between the first electronic component and the second electronic component, wherein the package molding material encapsulates said electrically-conductive formations.
 14. The method of claim 10, further comprising, after molding and singulating, mounting an electromagnetic shielding material over at least one of the first and second opposed surfaces of the first electronic component.
 15. The method of claim 10, wherein the first electronic component comprises a pressure sensor and wherein the method further comprises providing a pressure port at one or more of the opposed first and second surfaces.
 16. The method of claim 10, wherein the sacrificial support member comprises a tape.
 17. The method of claim 16, wherein singulating does not cut through the tape and removing is performed after singulating.
 18. The method of claim 10, wherein the first electronic component comprises a sensor and the second electronic component comprises a semiconductor integrated circuit chip.
 19. The method of claim 18, where the sensor is a Micro Electro-Mechanical Systems (MEMS) type sensor and wherein the semiconductor integrated circuit chip is an Application-Specific Integrated Circuit (ASIC). 